Pattern-dependent proximity matching/tuning including light manipulation by projection optics

ABSTRACT

Described herein are methods for matching the characteristics of a lithographic projection apparatus to a reference lithographic projection apparatus, where the matching includes optimizing projection optics characteristics. The projection optics can be used to shape wavefront in the lithographic projection apparatus. According to the embodiments herein, the methods can be accelerated by using linear fitting algorithm or using Taylor series expansion using partial derivatives of transmission cross coefficients (TCCs).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.61/412,376, filed Nov. 10, 2010, the contents of which are incorporatedby reference herein in its entirety.

FIELD OF THE INVENTION

The claimed invention relates to lithographic apparatuses and processes,and more particularly to tools for optimizing illumination sources, andprojection optics for use in lithographic apparatuses and processes.

BACKGROUND OF THE INVENTION

A lithographic projection apparatus can be used, for example, in themanufacture of integrated circuits (ICs). In such a case, a mask maycontain a circuit pattern corresponding to an individual layer of the IC(“design layout”), and this circuit pattern can be transferred onto atarget portion (e.g. comprising one or more dies) on a substrate (e.g.,silicon wafer) that has been coated with a layer of radiation-sensitivematerial (“resist”), by methods such as irradiating the target portionthrough the circuit pattern on the mask. In general, a single substratecontains a plurality of adjacent target portions to which the circuitpattern is transferred successively by the lithographic projectionapparatus, one target portion at a time. In one type of lithographicprojection apparatuses, the circuit pattern on the entire mask istransferred onto one target portion in one go; such an apparatus iscommonly referred to as a wafer stepper. In an alternative apparatus,commonly referred to as a step-and-scan apparatus, a projection beamscans over the mask in a given reference direction (the “scanning”direction) while synchronously moving the substrate parallel oranti-parallel to this reference direction. Different portions of thecircuit pattern on the mask are transferred to one target portionprogressively. Since, in general, the lithographic projection apparatuswill have a magnification factor M (generally <1), the speed F at whichthe substrate is moved will be a factor M times that at which theprojection beam scans the mask. More information with regard tolithographic devices as described herein can be gleaned, for example,from U.S. Pat. No. 6,046,792, incorporated herein by reference.

Prior to transferring the circuit pattern from the mask to thesubstrate, the substrate may undergo various procedures, such aspriming, resist coating and a soft bake. After exposure, the substratemay be subjected to other procedures, such as a post-exposure bake(PEB), development, a hard bake and measurement/inspection of thetransferred circuit pattern. This array of procedures is used as a basisto make an individual layer of a device, e.g., an IC. The substrate maythen undergo various processes such as etching, ion-implantation(doping), metallization, oxidation, chemo-mechanical polishing, etc.,all intended to finish off the individual layer of the device. Ifseveral layers are required in the device, then the whole procedure, ora variant thereof, will have to be repeated for each layer. Eventually,a device will be present in each target portion on the substrate. Thesedevices are then separated from one another by a technique such asdicing or sawing, whence the individual devices can be mounted on acarrier, connected to pins, etc.

As noted, microlithography is a central step in the manufacturing ofICs, where patterns formed on substrates define functional elements ofthe ICs, such as microprocessors, memory chips etc. Similar lithographictechniques are also used in the formation of flat panel displays,micro-electro mechanical systems (MEMS) and other devices.

As semiconductor manufacturing processes continue to advance, thedimensions of functional elements have continually been reduced whilethe amount of functional elements, such as transistors, per device hasbeen steadily increasing over decades, following a trend commonlyreferred to as “Moore's law”. At the current state of technology, layersof devices are manufactured using lithographic projection apparatusesthat project a design layout onto a substrate using illumination from adeep-ultraviolet illumination source, creating individual functionalelements having dimensions well below 100 nm, i.e. less than half thewavelength of the light from the illumination source.

This process in which features with dimensions smaller than theclassical resolution limit of a lithographic projection apparatus areprinted, is commonly known as low-k₁ lithography, according to theresolution formula CD=k₁×λ/NA, where λ, is the wavelength of radiationemployed (currently in most cases 248 nm or 193 nm), NA is the numericalaperture of projection optics in the lithographic projection apparatus,CD is the “critical dimension”—generally the smallest feature sizeprinted—and k₁ is an empirical resolution factor. In general, thesmaller k₁ the more difficult it becomes to reproduce a pattern on thewafer that resembles the shape and dimensions planned by a circuitdesigner in order to achieve particular electrical functionality andperformance. To overcome these difficulties, sophisticated fine-tuningsteps are applied to the lithographic projection apparatus as well as tothe design layout. These include, for example, but not limited to,optimization of NA and optical coherence settings, customizedillumination schemes, use of phase shifting masks, optical proximitycorrection (OPC, sometimes also referred to as “optical and processcorrection”) in the design layout, or other methods generally defined as“resolution enhancement techniques” (RET).

As one important example, OPC addresses the fact that the final size andplacement of an image of the design layout projected on the substratewill not be identical to, or simply depend only on the size andplacement of the design layout on the mask. It is noted that the terms“mask” and “reticle” are utilized interchangeably herein. Also, personskilled in the art will recognize that, especially in the context oflithography simulation/optimization, the term “mask” and “design layout”can be used interchangeably, as in lithography simulation/optimization,a physical mask is not necessarily used but a design layout can be usedto represent a physical mask. For the small feature sizes and highfeature densities present on some design layout, the position of aparticular edge of a given feature will be influenced to a certainextent by the presence or absence of other adjacent features. Theseproximity effects arise from minute amounts of light coupled from onefeature to another and/or non-geometrical optical effects such asdiffraction and interference. Similarly, proximity effects may arisefrom diffusion and other chemical effects during post-exposure bake(PEB), resist development, and etching that generally followlithography.

In order to ensure that the projected image of the design layout is inaccordance with requirements of a given target circuit design, proximityeffects need to be predicted and compensated for, using sophisticatednumerical models, corrections or pre-distortions of the design layout.The article “Full-Chip Lithography Simulation and Design Analysis—HowOPC Is Changing IC Design”, C. Spence, Proc. SPIE, Vol. 5751, pp 1-14(2005) provides an overview of current “model-based” optical proximitycorrection processes. In a typical high-end design almost every featureof the design layout requires some modification in order to achieve highfidelity of the projected image to the target design. Thesemodifications may include shifting or biasing of edge positions or linewidths as well as application of “assist” features that are intended toassist projection of other features.

Application of model-based OPC to a target design requires good processmodels and considerable computational resources, given the many millionsof features typically present in a chip design. However, applying OPC isgenerally not an “exact science”, but an empirical, iterative processthat does not always compensate for all possible proximity effect.Therefore, effect of OPC, e.g., design layouts after application of OPCand any other RET, need to be verified by design inspection, i.e.intensive full-chip simulation using calibrated numerical processmodels, in order to minimize the possibility of design flaws being builtinto the manufacturing of a mask. This is driven by the enormous cost ofmaking high-end masks, which run in the multi-million dollar range, aswell as by the impact on turn-around time by reworking or repairingactual masks once they have been manufactured.

Both OPC and full-chip RET verification may be based on numericalmodeling systems and methods as described, for example in, U.S. Pat. No.7,003,758 and an article titled “Optimized Hardware and Software ForFast, Full Chip Simulation”, by Y. Cao et al., Proc. SPIE, Vol. 5754,405 (2005).

In addition to optimization to design layouts or masks (e.g., OPC), theillumination source can also optimized, either jointly with maskoptimization or separately, in an effort to improve the overalllithography fidelity. Since the 1990s, many off-axis illuminationsources, such as annular, quadrupole, and dipole, have been introduced,and have provided more freedom for OPC design, thereby improving theimaging results, As is known, off-axis illumination is a proven way toresolve fine structures (i.e., target features) contained in the mask.However, when compared to a traditional illumination source, an off-axisillumination source usually provides less light intensity for the aerialimage (AI). Thus, it becomes necessary to attempt to optimize theillumination source to achieve the optimal balance between finerresolution and reduced light intensity. The terms “illumination source”and “source” are used interchangeably in this document.

Numerous illumination source optimization approaches can be found, forexample, in an article by Rosenbluth et al., titled “Optimum Mask andSource Patterns to Print A Given Shape”, Journal of Microlithography,Microfabrication, Microsystems 1(1), pp. 13-20, (2002). The source ispartitioned into several regions, each of which corresponds to a certainregion of the pupil spectrum. Then, the source distribution is assumedto be uniform in each source region and the brightness of each region isoptimized for process window. However, such an assumption that thesource distribution is uniform in each source region is not alwaysvalid, and as a result the effectiveness of this approach suffers. Inanother example set forth in an article by Granik, titled “SourceOptimization for Image Fidelity and Throughput”, Journal ofMicrolithography, Microfabrication, Microsystems 3(4), pp. 509-522,(2004), several existing source optimization approaches are overviewedand a method based on illuminator pixels is proposed that converts thesource optimization problem into a series of non-negative least squareoptimizations. Though these methods have demonstrated some successes,they typically require multiple complicated iterations to converge. Inaddition, it may be difficult to determine the appropriate/optimalvalues for some extra parameters, such as γ in Granik's method, whichdictates the trade-off between optimizing the source for wafer imagefidelity and the smoothness requirement of the source.

For low k₁ photolithography, optimization of both the source and mask isvery useful to ensure a viable process window for projection of criticalcircuit patterns. Some algorithms (e.g. Socha et. al. Proc. SPIE vol.5853, 2005, p. 180) discretize illumination into independent sourcepoints and mask into diffraction orders in the spatial frequency domain,and separately formulate a cost function (which is defined as a functionof selected design variables) based on process window metrics such asexposure latitude which could be predicted by optical imaging modelsfrom source point intensities and mask diffraction orders. The term“design variables” as used herein means a set of parameters of alithographic projection apparatus, for example, parameters a user of thelithographic projection apparatus can adjust. It should be appreciatedthat any characteristics of a lithographic projection apparatus,including those of the source, the mask, the projection optics, can beamong the design variables in the optimization. The cost function isoften a non-linear function of the design variables. Then standardoptimization techniques are used to minimize the cost function.

One problem with these algorithms that formulate a cost function is thatthey require a large number of full forward optical imaging modelsimulations before convergence on both optimal source and mask isreached. Optimizing the lithographic projection apparatus using a clip(which is defined as a portion of a design layout with calibrationfeatures that can be used for optimization of the lithographicprojection apparatus, as elaborated further in the detailed descriptionsection) of medium complexity can take weeks or even months on lateststandard PC hardware, which is generally considered impractical. Apractical optimization process generally costs less than about 24 hours.

Relatedly, the delay of EUV lithography and the pressure of everdecreasing design rules have driven semiconductor chipmakers to movedeeper into the low k₁ lithography era with existing 193 nm ArFlithography. Lithography towards lower k₁ puts heavy demands on RET,exposure tools, and the need for litho-friendly design. The 1.35 ArFhyper numerical apertures (NA) exposure tool will be the exposure toolfor chip manufactures to use in the next two years. To ensure thatcircuit design can be produced on to the substrate with workable processwindow; source-mask optimization (SMO) is becoming an important RET thatis required for 2× nm node.

A source and mask (design layout) optimization method and system thatallow for simultaneous optimization of the source and mask using a costfunction without constraints and within a practicable amount of time isdescribed in a commonly assigned International Patent Application No.PCT/US2009/065359, filed on Nov. 20, 2009, and published asWO2010/059954, titled “Fast Freeform Source and Mask Co-OptimizationMethod”, which is hereby incorporated by reference in its entirety.

New development in hardware and software of lithographic projectionapparatuses provides more flexibility by making projection opticstherein adjustable. The term “projection optics” as used herein shouldbe broadly interpreted as encompassing various types of optical systems,including refractive optics, reflective optics, apertures andcatadioptric optics, for example. The term “projection optics” may alsoinclude components operating according to any of these design types fordirecting, shaping or controlling the projection beam of radiation,collectively or singularly. The term “projection optics” may include anyoptical component in the lithographic projection apparatus, no matterwhere the optical component is located on an optical path of thelithographic projection apparatus. Projection optics can include opticalcomponents for shaping, adjusting and/or projecting light from thesource before the light passes the mask, and/or optical components forshaping, adjusting and/or projecting the light after the light passesthe mask. The projection optics generally exclude the source and themask.

For example, adjustable parameters (“knobs”) of the projection opticsmake it possible to shape light in more degrees of freedom (e.g.,wavefront shape, intensity distribution, etc.) and/or to accommodate awider range of conditions of the source and the mask (namely to providea larger process window (PW)), than what is offered by the existing SMOtechniques.

However, optimizing these additional knobs entails very high computationcost. Therefore, methods to simplify and accelerate optimization ofthese knobs related to the projection optics jointly with knobsassociated with the source and mask is desirable.

Therefore what is needed is a computationally-efficient comprehensiveoptimization method for characterizing a lithographic process based onwhich the setting of a lithographic apparatus (including setting of aprojection optics system) is decided and a mask is designed.

An additional benefit of having more adjustable parameters topre-optimize a lithographic projection apparatus is that it enables auser to tune the behavior of one lithographic projection apparatus inorder to match the behavior of another reference lithographic projectionapparatus or a desired preset scanner behavior (e.g., the behavior of avirtual scanner). Note that the term “scanner” is used broadly in thisapplication to describe scanning-type or any other type of lithographicprojection apparatus. In co-pending co-owned patent application, titled,“Methods and System for Model-Based Generic Matching and Tuning,” USpublication no. 2010/0146475 to Cao et al., behavior matching/tuning hasbeen discussed, but the adjustment parameters (“knobs”) were mainlylinear parameters, such as illumination source intensity parameters.However, in order to handle non-linear effects such as the effect ofprojection optics in shaping the imaging light, additional non-linearadjustment parameters are to be included in the matching/tuningmethodology as well. Further, the previous matching/tuning methods usedmostly tuning parameters that are independent from the patterns in thedesign layout that are to be imaged.

What is needed is a more comprehensive behavior matching/tuningmethodology that integrates non-linear multi-variable optimizationinvolving characteristics of illumination source and projection optics.

BRIEF SUMMARY OF THE INVENTION

Embodiments as described herein provide methods for improving/optimizinga lithographic projection apparatus including improving/optimizingprojection optics therein, and preferably including the capability ofoptimizing a source, a mask, and the projection optics, simultaneouslyor alternatively. The projection optics is sometimes referred to as“lens”, and therefore the joint optimization process may be termedsource mask lens optimization (SMLO). Another term used to describe theSMLO process is source mask pupil optimization (SMPO), as in certainembodiments, lens optimization is done for the pupil plane of theprojection optics. However, the scope of the invention is not restrictedto optimization in the pupil plane only. SMLO is desirable over existingsource mask optimization process (SMO) or other optimization processesthat does not explicitly include the optimization of projection optics,partially because including the projection optics in the optimizationcan lead to a larger process window by introducing a plurality ofadjustable characteristics of the projection optics. The projectionoptics can be used to shape wavefront in the lithographic projectionapparatus. According to the embodiments herein, the optimization can beaccelerated by numerical techniques. Although adjustable characteristicsof the projection optics, the source and the mask are used in thedescription of the embodiments, other adjustable characteristics of thelithographic projection apparatus, such as, dose and focus, can beadjusted in the optimization.

The embodiments herein optimize the lithographic projection apparatus byminimizing a suitable cost function of design variables that can becharacteristics of the source, projection optics, and the mask/designlayout. Usually, when the optimization is a part of a matching/tuningmethodology, then the design variables of the mask/design layout arekept fixed, while the design variables of the source and the projectionoptics are tuned. Non-limiting examples of the cost function are given,including cost functions that represent a difference in lithographicresponse between a current lithographic process and a referencelithographic process. Other forms of the cost function are also possibleand can accommodate a wide variety of lithography metrics. The costfunction can be a function of the design variables of the to-be-tunedlithography process. Non-linear effects of projection optics isbuilt-into the cost function by choosing appropriate design variables.

The optimization process gives additional flexibility in terms ofmatching/tuning the behavior of the lithographic projection apparatus toa physical reference scanner's behavior or a desired preset behavior ofa virtual reference scanner. In the subsequent description, the genericterms “scanner-T” and “scanner-R” are used to broadly describe ato-be-tuned lithographic projection apparatus, and a referencelithographic projection apparatus (physical or virtual), respectively.

Behavior matching can be useful for correcting behavior differencesbetween two lithographic projection apparatuses due to variations ofmanufacturing these apparatuses, or correcting deviation of behaviors ofone lithographic projection apparatus over time due to factors such astemperatures, wear, aging, chemical and physical properties of resist,mask, etc. In the simulation domain, the behavior of the referencelithographic projection apparatus may be available a priori as areference model, i.e. the reference model represents the behavior of avirtual scanner. When comparing behavior with a physical scanner, thesame type of scanner (i.e. same model of scanner) or a different type ofscanner (i.e. a different model of scanner) may be used as thereference. When a virtual scanner's behavior model is used as referencemodel, the reference model may be based on a customized behavior that anend-user wants, or an ‘ideal’ or desired behavior that produces apredefined process window or produces favorable lithographic responses.For example, a particular behavior of an apparatus may be modeled as arelationship between a design layout to a resist image on a referencesubstrate generated by projecting the design layout onto the substrateusing the lithographic projection apparatus. The resist image can berepresented by, for example, various characteristics of the resist image(e.g., resist contours, CD, edge placement error). The cost function isflexible enough to be adapted to all the various possibilities ofbehavior matching/tuning mentioned above.

BRIEF DESCRIPTION OF THE DRAWINGS

The above aspects and other aspects and features of the presentinvention will become apparent to those ordinarily skilled in the artupon review of the following description of specific embodiments inconjunction with the accompanying figures, wherein:

FIG. 1 is a block diagram of various subsystems of a lithographicprojection apparatus;

FIG. 2 is a block diagram of simulation models corresponding to thesubsystems in FIG. 1;

FIG. 3 is a flow diagram illustrating aspects of an example methodologyof cost function optimization according to embodiments;

FIG. 4 is a flow diagram illustrating aspects of an example methodologyof matching behaviors of a lithographic projection apparatus accordingto embodiments.

FIGS. 5-6 show example flow diagrams of various optimization processes,according to embodiments of the present invention.

FIG. 7 shows a pattern-dependent matching/tuning flow diagram accordingto an embodiment of the present invention.

FIG. 8 is a block diagram of an example computer system in whichembodiments can be implemented;

FIG. 9 is a schematic diagram of a lithographic projection apparatus towhich embodiments are applicable.

DETAILED DESCRIPTION

Although specific reference may be made in this text to the use of theinvention in the manufacture of ICs, it should be explicitly understoodthat the invention has many other possible applications. For example, itmay be employed in the manufacture of integrated optical systems,guidance and detection patterns for magnetic domain memories,liquid-crystal display panels, thin-film magnetic heads, etc. Theskilled artisan will appreciate that, in the context of such alternativeapplications, any use of the terms “reticle”, “wafer” or “die” in thistext should be considered as interchangeable with the more general terms“mask”, “substrate” and “target portion”, respectively.

In the present document, the terms “radiation” and “beam” are used toencompass all types of electromagnetic radiation, including ultravioletradiation (e.g. with a wavelength of 365, 248, 193, 157 or 126 nm) andEUV (extreme ultra-violet radiation, e.g. having a wavelength in therange 5-20 nm).

The term “optimizing” and “optimization” as used herein mean adjusting alithographic projection apparatus such that results and/or processes oflithography have more desirable characteristics, such as higher accuracyof projection of design layouts on a substrate, larger process windows,etc.

Further, the lithographic projection apparatus may be of a type havingtwo or more substrate tables (and/or two or more mask tables). In such“multiple stage” devices the additional tables may be used in parallel,or preparatory steps may be carried out on one or more tables while oneor more other tables are being used for exposures. Twin stagelithographic projection apparatuses are described, for example, in U.S.Pat. No. 5,969,441, incorporated herein by reference.

The mask referred to above comprise design layouts. The design layoutscan be generated utilizing CAD (computer-aided design) programs, thisprocess often being referred to as EDA (electronic design automation).Most CAD programs follow a set of predetermined design rules in order tocreate functional design layouts/masks. These rules are set byprocessing and design limitations. For example, design rules define thespace tolerance between circuit devices (such as gates, capacitors,etc.) or interconnect lines, so as to ensure that the circuit devices orlines do not interact with one another in an undesirable way. The designrule limitations are typically referred to as “critical dimensions”(CD). A critical dimension of a circuit can be defined as the smallestwidth of a line or hole or the smallest space between two lines or twoholes. Thus, the CD determines the overall size and density of thedesigned circuit. Of course, one of the goals in integrated circuitfabrication is to faithfully reproduce the original circuit design onthe substrate (via the mask).

The term mask as employed in this text may be broadly interpreted asreferring to generic patterning means that can be used to endow anincoming radiation beam with a patterned cross-section, corresponding toa pattern that is to be created in a target portion of the substrate;the term “light valve” can also be used in this context. Besides theclassic mask (transmissive or reflective; binary, phase-shifting,hybrid, etc.), examples of other such patterning means include:

-   -   a programmable mirror array. An example of such a device is a        matrix-addressable surface having a viscoelastic control layer        and a reflective surface. The basic principle behind such an        apparatus is that (for example) addressed areas of the        reflective surface reflect incident light as diffracted light,        whereas unaddressed areas reflect incident light as undiffracted        light. Using an appropriate filter, the said undiffracted light        can be filtered out of the reflected beam, leaving only the        diffracted light behind; in this manner, the beam becomes        patterned according to the addressing pattern of the        matrix-addressable surface. The required matrix addressing can        be performed using suitable electronic means. More information        on such mirror arrays can be gleaned, for example, from U.S.        Pat. Nos. 5,296,891 and 5,523,193, which are incorporated herein        by reference.    -   a programmable LCD array. An example of such a construction is        given in U.S. Pat. No. 5,229,872, which is incorporated herein        by reference.

As a brief introduction, FIG. 1 illustrates an exemplary lithographicprojection apparatus 10. Major components are an illumination source 12,which may be a deep-ultraviolet excimer laser source or other type ofsources including extreme ultra violet (EUV) sources, illuminationoptics which define the partial coherence (denoted as sigma) and whichmay include optics 14, 16 a and 16 b that shape light from the source12; a mask or reticle 18; and transmission optics 16 c that project animage of the reticle pattern onto a substrate plane 22. An adjustablefilter or aperture 20 at the pupil plane of the projection optics mayrestrict the range of beam angles that impinge on the substrate plane22, where the largest possible angle defines the numerical aperture ofthe projection optics NA=sin(Θ_(max)).

In an optimization process of a system, a figure of merit of the systemcan be represented as a cost function. The optimization process boilsdown to a process of finding a set of parameters (design variables) ofthe system that minimizes the cost function. The cost function can haveany suitable form depending on the goal of the optimization. Forexample, the cost function can be weighted root mean square (RMS) ofdeviations of certain characteristics (at evaluation points) of thesystem with respect to the intended values (e.g., ideal values) of thesecharacteristics; the cost function can also be the maximum of thesedeviations. The design variables of the system can be confined to finiteranges and/or be interdependent due to practicalities of implementationsof the system. In case of a lithographic projection apparatus, theconstraints are often associated with physical properties andcharacteristics of the hardware such as tunable ranges, and/or maskmanufacturability design rules, and the evaluation points can includephysical points on a resist image on a substrate, as well asnon-physical characteristics such as dose and focus.

In a lithographic projection apparatus, a source provides illumination(i.e. light); projection optics direct and shapes the illuminationthrough a mask and onto a substrate. The term “projection optics” isbroadly defined here to include any optical component that may alter thewavefront of the radiation beam. For example, projection optics mayinclude at least some of the components 14, 16 a, 16 b and 16 c. Anaerial image (AI) is the light intensity distribution on the substrate.A resist layer on the substrate is exposed and the aerial image istransferred to the resist layer as a latent “resist image” (RI) therein.The resist image (RI) can be defined as a spatial distribution ofsolubility of the resist in the resist layer. A resist model can be usedto calculate the resist image from the aerial image, an example of whichcan be found in commonly assigned U.S. Patent Application Publ. No.2009/0157360, disclosure of which is hereby incorporated by reference inits entirety. The resist model is related only to properties of theresist layer (e.g., effects of chemical processes which occur duringexposure, PEB and development). Optical properties of the lithographicprojection apparatus (e.g., properties of the source, the mask and theprojection optics) dictate the aerial image. Since the mask used in thelithographic projection apparatus can be changed, it is desirable toseparate the optical properties of the mask from the optical propertiesof the rest of the lithographic projection apparatus including at leastthe source and the projection optics.

An exemplary flow chart for simulating lithography in a lithographicprojection apparatus is illustrated in FIG. 2. A source model 31represents optical characteristics (including light intensitydistribution and/or phase distribution) of the source. A projectionoptics model 32 represents optical characteristics (including changes tothe light intensity distribution and/or the phase distribution caused bythe projection optics) of the projection optics. The source model 31 andthe projection optics model 32 can be combined, as explained laterherein, into a transmission cross coefficient (TCC) model 34. A designlayout model 35 represents optical characteristics (including changes tothe light intensity distribution and/or the phase distribution caused bya given design layout 33) of a design layout 33, which is therepresentation of an arrangement of features on a mask. An aerial image36 can be simulated from the transmission cross coefficient 34 and thedesign layout model 35. A resist image 37 can be simulated from theaerial image 36 using a resist model 37. Simulation of lithography can,for example, predict contours and CDs in the resist image.

More specifically, it is noted that the source model 31 can representthe optical characteristics of the source that include, but not limitedto, NA-sigma (σ) settings as well as any particular illumination sourceshape (e.g. off-axis light sources such as annular, quadrupole, anddipole, etc.). The projection optics model 32 can represent the opticalcharacteristics of the of the projection optics that include aberration,distortion, refractive indexes, physical sizes, physical dimensions,etc. The design layout model 35 can also represent physical propertiesof a physical mask, as described, for example, in U.S. Pat. No.7,587,704, which is incorporated by reference in its entirety. Theobjective of the simulation is to accurately predict, for example, edgeplacements and CDs, which can then be compared against an intendeddesign. The intended design is generally defined as a pre-OPC designlayout which can be provided in a standardized digital file format suchas GDSII or OASIS or other file format.

From this design layout, one or more portions may be identified, whichare referred to as “clips”. In a specific embodiment of the invention, afull set of clips is extracted, which represents the complicatedpatterns in the design layout (typically about 50 to 1000 clips,although any number of clips may be used). As will be appreciated bythose skilled in the art, these patterns or clips represent smallportions (i.e. circuits, cells or patterns) of the design and especiallythe clips represent small portions for which particular attention and/orverification is needed. In other words, clips may be the portions of thedesign layout where critical features are identified either byexperience (including clips provided by a customer), by trial and error,or by running a full-chip simulation. Clips usually contain one or moretest patterns or gauge patterns.

An initial larger set of clips may be provided a priori by a customerbased on known critical feature areas in a design layout which requireparticular image optimization. Alternatively, in another embodiment ofthe present invention, the initial larger set of clips may be extractedfrom the entire design layout by using some kind of automated (such as,machine vision) or manual algorithm that identifies the critical featureareas.

To reduce the overall computation burden, various ways of optimizationcan be envisioned. In one embodiment, first a set of clips is selectedby a pattern selection method based on diffraction signature analysis orany other method, and then the SMLO process is performed. Alternatively,first a full chip simulation is performed, ‘hot spots’ and/or ‘warmspots’ are identified from the full chip simulation, and then a patternselection step is performed. The optimization is done based on theselected patterns. The pattern selection algorithm (based on diffractionsignature analysis or other methods) can be seamlessly integrated withthe SMLO process. One example method is described further with respectto FIG. 7.

A general method of optimizing the lithography projection apparatususing SMLO, according to an embodiment, is illustrated in FIG. 3. Thismethod comprises a step 302 of defining a multi-variable cost functionof a plurality of design variables. At least some of the designvariables are characteristics of the projection optics, as shown in step300B. Other design variables may be associated with illumination source(step 300A) and the design layout (step 300C), although inmatching/tuning methodologies discussed herein, usually the designlayout is kept fixed, i.e. the design variables represent theillumination source and the projection optics, while the characteristicsof the design layout take fixed values. In step 304, the designvariables are adjusted so that the cost function is moved towardsconvergence. In step 306, it is determined whether a predefinedtermination condition is satisfied. The predetermined terminationcondition may include various possibilities, i.e. the cost function maybe minimized or maximized, as required by the numerical technique used,the value of the cost function becomes equal to a threshold value orcrosses the threshold value, the value of the cost function reacheswithin a preset error limit, a predefined computation time elapses, or apreset number of iterations is reached. If either of the conditions instep 306 is satisfied, the method ends. If none of the conditions instep 306 is satisfied, the step 304 and 306 are iteratively repeateduntil a desired result is obtained.

In a lithographic projection apparatus, the source, mask and projectionoptics can be optimized alternatively (referred to as “AlternativeOptimization”) or optimized simultaneously (referred to as “SimultaneousOptimization”, or “Co-optimization”), according to embodiments. Theterms “simultaneous”, “simultaneously”, “joint” and “jointly” as usedherein mean that the design variables of the characteristics of thesource, mask, projection optics and/or any other design variables, areallowed to change at the same time. The term “alternative” and“alternatively” as used herein mean that not all of the design variablesare allowed to change at the same time. In FIG. 3, step 304 may indicatesimultaneous optimization, or alternative optimization.

In co-owned provisional application No. 61/412,372, titled,“Optimization of Source, Mask, and Projection Optics,” details ofvarious optimization techniques are elaborated including the detailedmathematical framework. The entire provisional application No.61/412,372 is incorporated by reference herein. The present applicationemphasizes on how a behavior matching between a to-be-tuned lithographicprojection apparatus model an a reference lithographic projectionapparatus model seamlessly integrates the SMLO process.

The following section describes the mathematical definition of costfunction only in general terms, as a non-limiting example.

In a lithographic projection apparatus, a cost function can be expressedas

$\begin{matrix}{{{CF}\left( {z_{1},z_{2},\ldots\mspace{14mu},z_{N}} \right)} = {\sum\limits_{p = 1}^{P}{w_{p}{f_{p}^{2}\left( {z_{1},z_{2},\ldots\mspace{14mu},z_{N}} \right)}}}} & \left( {{Eq}.\mspace{14mu} 1} \right)\end{matrix}$wherein (z₁, z₂, . . . , z_(N)) are N design variables or valuesthereof; f_(p)(z₁, z₂, . . . , z_(N)) is a difference between an actualvalue and an intended value of a characteristic at the p-th evaluationpoint for a set of values of the design variables of (z₁, z₂, . . . ,z_(N)). w_(p) is a weight constant assigned to the p-th evaluationpoint. An evaluation point or pattern more critical than others can beassigned a higher w_(p) value. Patterns and/or evaluation points withlarger number of occurrences may be assigned a higher w_(p) value, too.Examples of the evaluation points can be any physical point or patternon the wafer, or any point on a virtual design layout, or resist image,or aerial image. The cost function may represent any suitablecharacteristics of the lithographic projection apparatus or thesubstrate, for instance, focus, CD, image shift, image distortion, imagerotation, etc. Since it is the resist image that often dictates thecircuit pattern on a substrate, the cost function often includesfunctions that represent some characteristics of the resist image. Forexample, f_(p)(z₁, z₂, . . . , z_(N)) of such an evaluation point can besimply a distance between a point in the resist image to an intendedposition of that point (i.e., edge placement error EPE_(p)(z₁, z₂, . . ., z_(N))). The design variables can be any adjustable parameters such asadjustable parameters of the source, the mask, the projection optics,dose, focus, etc. Preferably, at least some of the design variables areadjustable characteristics of the projection optics. The projectionoptics may include components collectively called as “wavefrontmanipulator” that can be used to adjust shapes of a wavefront andintensity distribution and/or phase shift of the irradiation beam. Theprojection optics preferably can adjust a wavefront and intensitydistribution at any location along an optical path of the lithographicprojection apparatus, such as before the mask, near a pupil plane, nearan image plane, near a focal plane. The projection optics can be used tocorrect or compensate for certain distortions (or aberrations) of thewavefront and intensity distribution caused by, for example, the source,the mask, temperature variation in the lithographic projectionapparatus, thermal expansion of components of the lithographicprojection apparatus. Adjusting the wavefront and intensity distributioncan change values of the evaluation points and the cost function. Suchchanges can be simulated from a model or actually measured.

It should be noted that the normal weighted root mean square (RMS) off_(p)(z₁, z₂, . . . , z_(N)) is defined as

$\sqrt{\frac{1}{P}{\sum\limits_{p = 1}^{P}{w_{p}{f_{p}^{2}\left( {z_{1},z_{2},\ldots\mspace{14mu},z_{N}} \right)}}}},$therefore, minimizing the weighted RMS of f_(p)(z₁, z₂, . . . , z_(N))is equivalent to minimizing the cost function

${{{CF}\left( {z_{1},z_{2},\ldots\mspace{14mu},z_{N}} \right)} = {\sum\limits_{p = 1}^{P}{w_{p}{f_{p}^{2}\left( {z_{1},z_{2},\ldots\mspace{14mu},z_{N}} \right)}}}},$defined in Eq. 1. Thus the weighted RMS of f_(p)(z₁, z₂, . . . , z_(N))and Eq. 1 may be utilized interchangeably for notational simplicityherein.

In behavior matching/tuning, the intended values of the cost functioncan be obtained from the reference lithographic projection apparatus(physical scanner) or desired virtual scanner behavior (Scanner-R). Whenthe cost function is minimized, the behavior of one lithographicprojection apparatus (Scanner-T) is best matched to desired behaviorsobtained from Scanner-R. In an example, the cost function can beexpressed as a function that reflects the difference between a resistimage produced from a design layout (or portion thereof) by theScanner-T and a reference resist image produced by the same designlayout (or portion thereof) by the scanner-R. Usually, thecharacteristics of the Scanner-R is kept constant, and the designvariables of the Scanner-T are tuned. Other examples of the costfunction include, but not limited to, the difference between theCritical Dimensions (CDs), or contour differences, or EPEs from the twoscanners. Further, the cost function may also include scanner behaviordifference from different Process Window (PW) conditions, in order tomatch/tune the scanner behavior across certain area of PW. The designlayout can be any suitable design layout of interest, for example, atypical circuit pattern, a test pattern, a dense pattern, and/or acritical pattern. The gauges or test patterns from the design layoutused for producing the resist image can be selected using methodsdescribed in commonly assigned U.S. patent application Ser. No.12/613,244, published on May 13, 2010 as U.S. Patent ApplicationPublication 2010/0122225, which is incorporated by reference in itsentirety.

FIG. 4 shows a flow chart of the method of matching behaviors asdescribed above. The design variables 400B are characteristics of theprojection optics. Some of the design variables 400A can becharacteristics of the illumination source. Characteristics of the maskdesign layout are identified in step 400C. The to-be-tuned resist imageproduced in step 401A is a function of at least some of the designvariables mentioned above. In step 401B, a reference resist image isprovided. In step 402, a cost function is defined as a function ofdifference between the to-be-tuned resist image and the reference resistimage. An example of such a cost function is given in Appendix A(equation 14) submitted with the provisional application No. 61/412,376,which is incorporated herein by reference in its entirety. Since theresist image is a function of the design variables, the cost function isthus a function of the design variables. In step 404, the designvariables are adjusted (simultaneously or alternatively) so that thecost function is moved towards convergence. In step 406, it isdetermined whether a predefined termination condition is satisfied, asdefined in step 306 in FIG. 3. An additional termination condition incase of matching/tuning process flow is when a satisfactory matchingwith a reference scanner behavior is obtained, as further discussed withh reference to FIG. 7. If either of the conditions in step 406 issatisfied, the method ends. If none of the conditions in step 406 issatisfied, the steps 404 and 406 are repeated until a desired result isobtained.

As discussed before, optimization of the cost function (CF) is at thecenter of the pattern matching/tuning, and the cost function canrepresent resist image or any other characteristics.

FIG. 5 shows one exemplary method of pattern-matching/tuning using SMLO,where a cost function is minimized. In step 502, initial values ofdesign variables are obtained, including their tuning ranges, if any. Instep S504, the multi-variable cost function is set up. In step S506, thecost function is expanded within a small enough neighborhood around thestarting point value of the design variables for the first iterativestep (i=0). In step S508, standard multi-variable optimizationtechniques are applied to minimize the cost function. Note that theoptimization problem can apply constraints, such as tuning ranges,during the optimization process in S508 or at a later stage in theoptimization process. Step S520 indicates that each iteration is donefor the given test patterns (also known as “gauges”) for the identifiedevaluation points that have been selected to optimize the lithographicprocess. In step S510, a lithographic response is predicted. In stepS512, the result of step S510 is compared with a desired or ideallithographic response value obtained in step S522. If the terminationcondition is satisfied in step S514, i.e. the optimization generates alithographic response value sufficiently close to the desired value, andthen the final value of the design variables is outputted in step S518.Various termination condition examples are discussed with respect toFIGS. 3 and 4. The output step may also include outputting otherfunctions using the final values of the design variables, such asoutputting a wavefront aberration-adjusted map at the pupil plane (orother planes) an optimized source map, etc. If the termination conditionis not satisfied, then in step S516, the values of the design variablesis updated with the result of the i-th iteration, and the process goesback to step S506. The entire mathematical process of FIG. 5 iselaborated in co-pending co-owned provisional application titled,“Optimization of source, mask, and projection optics,” (application No.61/412,372), filed on Nov. 10, 2010.

The linear approximation used in step S506 only holds in a smallvicinity of (z_(1i), z_(2i), . . . , z_(Ni)) in the i-th iteration. Iff_(p)(z₁, z₂, . . . , z_(N)) is highly non-linear to the designvariables (z₁, z₂, . . . , z_(N)), optimization using the linearapproximation may take too many iterations and/or lead to a localminimum of the cost function CF(z₁, z₂, . . . , z_(N)) instead of aglobal minimum. This problem can be alleviated by expanding the costfunction CF(z₁, z₂, . . . , z_(N)) into higher-order-polynomials of somedesign variables, especially those to which the cost function is highlynon-linear, such as cost functions involving aberrations introduced bythe projection optics. FIG. 6 shows an example flow diagram illustratingkey steps of another matching/tuning process with SMLO. Many of thesteps of FIG. 6 are very similar to corresponding steps in FIG. 5,unless explained otherwise here. One major difference is that in stepS604, the multi-variable cost function is expressed as a higher-order(such as quadratic) polynomial including fitting coefficients relatedto, for example, partial derivatives of transmission cross coefficients(TCCs). In step S606 TCC is expanded around starting point for eachiteration, and in step S607, aerial image, resist image and edgeplacement error (EPE) are expanded. The rest of the steps are similar tothe corresponding steps described in FIG. 5. From the elucidation aboveit will be apparent to the skilled person that in a specific embodimentof the invention, the number of iterations may even be one, resulting ina single calculation sequence. This may, for example, occur when thedescription of some design variables initially is sufficient enough thatthe predefined termination condition is satisfied after the singlecalculation. The entire mathematical process of FIG. 6 is elaborated inco-pending co-owned provisional application No. 61/412,372.

FIG. 7 shows a flow diagram where the appropriate optimization processdiscussed in FIGS. 5 and 6 (i.e. whichever optimization process isselected) is integrated to a framework of scanner matching/tuning. Instep S702, models of scanner-T and scanner-R are obtained. In step S704,matching quality is simulated. In step S706 it is determined if thematching results are satisfactory. If yes, then the process ends in stepS718. The output of the step S718 may be design variables that producethe best matching of the behavior of scanner-T with that of scanner-R.If not, then hot spots, which are patterns with difference between thetwo scanners larger than a preset limit, and/or warm spots, which arepatterns with difference between the two scanners close to the presetlimit for hot spots, are identified in step S708 from the matchingresults of step S704. In step S710, the patterns with identified hotspots and/or warm spots are converted to gauges or test patterns, and instep S712, the gauge set is updated with the new gauges from step S710.The gauge set of S712 may also have generic patterns, critical patterns,or dense patterns, preselected by a customer or the lithography designerbased on previous experience. An optional pattern selection algorithmmay be performed (step S714) to reduce the number of redundant gauges.Pattern selection may be done using diffraction signature analysis, orother mathematical techniques. An example of pattern selection algorithmis disclosed in co-pending co-owned application published US2010/0122225. The method of matching behaviors using SMLO is repeated instep S716 with the new set of gauges using the process of FIG. 5 or FIG.6, as applicable. The new gauges may be, for example, a set of gaugesthat produce resist image (or other lithographic responses such as CD,EPE, and etc) with measurement values sufficiently different from theprevious measurement values (e.g., the difference is bigger than apreset limit). The design variables (i.e. turning knobs) are optimizedto simulate the behavior of the scanner-T or the differential behaviorwith respect to scanner-R. The steps S704-S716 are repeated until asatisfactory matching is obtained. Satisfactory matching with areference behavior is used as an additional termination condition (ontop of the termination conditions described in FIG. 3) in FIG. 7.

Persons skilled in the art will appreciate that models of Scanner-T andScanner-R do not have t have the exact same design variables. This maytranslate to mean that a different type of physical scanner or a virtualscanner may be used as reference when tuning a specific type ofScanner-T. Moreover, Scanner-R design variables (or characteristics) maybe kept constant, while only the design variables of Scanner-T aretuned.

FIG. 8 is a block diagram that illustrates a computer system 100 whichcan assist in implementing the optimization methods and flows disclosedherein. Computer system 100 includes a bus 102 or other communicationmechanism for communicating information, and a processor 104 (ormultiple processors 104 and 105) coupled with bus 102 for processinginformation. Computer system 100 also includes a main memory 106, suchas a random access memory (RAM) or other dynamic storage device, coupledto bus 102 for storing information and instructions to be executed byprocessor 104. Main memory 106 also may be used for storing temporaryvariables or other intermediate information during execution ofinstructions to be executed by processor 104. Computer system 100further includes a read only memory (ROM) 108 or other static storagedevice coupled to bus 102 for storing static information andinstructions for processor 104. A storage device 110, such as a magneticdisk or optical disk, is provided and coupled to bus 102 for storinginformation and instructions.

Computer system 100 may be coupled via bus 102 to a display 112, such asa cathode ray tube (CRT) or flat panel or touch panel display fordisplaying information to a computer user. An input device 114,including alphanumeric and other keys, is coupled to bus 102 forcommunicating information and command selections to processor 104.Another type of user input device is cursor control 116, such as amouse, a trackball, or cursor direction keys for communicating directioninformation and command selections to processor 104 and for controllingcursor movement on display 112. This input device typically has twodegrees of freedom in two axes, a first axis (e.g., x) and a second axis(e.g., y), that allows the device to specify positions in a plane. Atouch panel (screen) display may also be used as an input device.

According to one embodiment of the invention, portions of theoptimization process may be performed by computer system 100 in responseto processor 104 executing one or more sequences of one or moreinstructions contained in main memory 106. Such instructions may be readinto main memory 106 from another computer-readable medium, such asstorage device 110. Execution of the sequences of instructions containedin main memory 106 causes processor 104 to perform the process stepsdescribed herein. One or more processors in a multi-processingarrangement may also be employed to execute the sequences ofinstructions contained in main memory 106. In alternative embodiments,hard-wired circuitry may be used in place of or in combination withsoftware instructions to implement the invention. Thus, embodiments ofthe invention are not limited to any specific combination of hardwarecircuitry and software.

The term “computer-readable medium” as used herein refers to any mediumthat participates in providing instructions to processor 104 forexecution. Such a medium may take many forms, including but not limitedto, non-volatile media, volatile media, and transmission media.Non-volatile media include, for example, optical or magnetic disks, suchas storage device 110. Volatile media include dynamic memory, such asmain memory 106. Transmission media include coaxial cables, copper wireand fiber optics, including the wires that comprise bus 102.Transmission media can also take the form of acoustic or light waves,such as those generated during radio frequency (RF) and infrared (IR)data communications. Common forms of computer-readable media include,for example, a floppy disk, a flexible disk, hard disk, magnetic tape,any other magnetic medium, a CD-ROM, DVD, any other optical medium,punch cards, paper tape, any other physical medium with patterns ofholes, a RAM, a PROM, and EPROM, a FLASH-EPROM, any other memory chip orcartridge, a carrier wave as described hereinafter, or any other mediumfrom which a computer can read.

Various forms of computer readable media may be involved in carrying oneor more sequences of one or more instructions to processor 104 forexecution. For example, the instructions may initially be borne on amagnetic disk of a remote computer. The remote computer can load theinstructions into its dynamic memory and send the instructions over atelephone line using a modem. A modem local to computer system 100 canreceive the data on the telephone line and use an infrared transmitterto convert the data to an infrared signal. An infrared detector coupledto bus 102 can receive the data carried in the infrared signal and placethe data on bus 102. Bus 102 carries the data to main memory 106, fromwhich processor 104 retrieves and executes the instructions. Theinstructions received by main memory 106 may optionally be stored onstorage device 110 either before or after execution by processor 104.

Computer system 100 also preferably includes a communication interface118 coupled to bus 102. Communication interface 118 provides a two-waydata communication coupling to a network link 120 that is connected to alocal network 122. For example, communication interface 118 may be anintegrated services digital network (ISDN) card or a modem to provide adata communication connection to a corresponding type of telephone line.As another example, communication interface 118 may be a local areanetwork (LAN) card to provide a data communication connection to acompatible LAN. Wireless links may also be implemented. In any suchimplementation, communication interface 118 sends and receiveselectrical, electromagnetic or optical signals that carry digital datastreams representing various types of information.

Network link 120 typically provides data communication through one ormore networks to other data devices. For example, network link 120 mayprovide a connection through local network 122 to a host computer 124 orto data equipment operated by an Internet Service Provider (ISP) 126.ISP 126 in turn provides data communication services through theworldwide packet data communication network, now commonly referred to asthe “Internet” 128. Local network 122 and Internet 128 both useelectrical, electromagnetic or optical signals that carry digital datastreams. The signals through the various networks and the signals onnetwork link 120 and through communication interface 118, which carrythe digital data to and from computer system 100, are exemplary forms ofcarrier waves transporting the information.

Computer system 100 can send messages and receive data, includingprogram code, through the network(s), network link 120, andcommunication interface 118. In the Internet example, a server 130 mighttransmit a requested code for an application program through Internet128, ISP 126, local network 122 and communication interface 118. Inaccordance with the invention, one such downloaded application providesfor the illumination optimization of the embodiment, for example. Thereceived code may be executed by processor 104 as it is received, and/orstored in storage device 110, or other non-volatile storage for laterexecution. In this manner, computer system 100 may obtain applicationcode in the form of a carrier wave.

FIG. 9 schematically depicts an exemplary lithographic projectionapparatus whose illumination source could be optimized utilizing themethods described herein. The apparatus comprises:

-   -   a radiation system IL, for supplying a projection beam B of        radiation. In this particular case, the radiation system also        comprises a radiation source SO;    -   a first object table (mask table) MT provided with a mask holder        for holding a mask MA (e.g., a reticle), and connected to first        positioning means for accurately positioning the mask with        respect to item PS;    -   a second object table (substrate table) WT provided with a        substrate holder for holding a substrate W (e.g., a        resist-coated silicon wafer), and connected to second        positioning means for accurately positioning the substrate with        respect to item PS;    -   a projection system (“lens”) PS (e.g., a refractive, catoptric        or catadioptric optical system) for imaging an irradiated        portion of the mask MA onto a target portion C (e.g., comprising        one or more dies) of the substrate W.

As depicted herein, the apparatus is of a transmissive type (i.e., has atransmissive mask). However, in general, it may also be of a reflectivetype, for example (with a reflective mask). Alternatively, the apparatusmay employ another kind of patterning means as an alternative to the useof a mask; examples include a programmable mirror array or LCD matrix.

The source SO (e.g., a mercury lamp or excimer laser) produces a beam ofradiation. This beam is fed into an illumination system (illuminator)IL, either directly or after having traversed conditioning means, suchas a beam expander Ex, for example. The illuminator IL may compriseadjusting means AD for setting the outer and/or inner radial extent(commonly referred to as σ-outer and σ-inner, respectively) of theintensity distribution in the beam. In addition, it will generallycomprise various other components, such as an integrator IN and acondenser CO. In this way, the beam B impinging on the mask MA has adesired uniformity and intensity distribution in its cross-section.

It should be noted with regard to FIG. 9 that the source SO may bewithin the housing of the lithographic projection apparatus (as is oftenthe case when the source SO is a mercury lamp, for example), but that itmay also be remote from the lithographic projection apparatus, theradiation beam that it produces being led into the apparatus (e.g., withthe aid of suitable directing mirrors); this latter scenario is oftenthe case when the source SO is an excimer laser (e.g., based on KrF, ArFor F₂ lasing).

The beam PB subsequently intercepts the mask MA, which is held on a masktable MT. Having traversed the mask MA, the beam B passes through thelens PS, which focuses the beam B onto a target portion C of thesubstrate W. With the aid of the second positioning means (andinterferometric measuring means IF), the substrate table WT can be movedaccurately, e.g. so as to position different target portions C in thepath of the beam PB. Similarly, the first positioning means can be usedto accurately position the mask MA with respect to the path of the beamB, e.g., after mechanical retrieval of the mask MA from a mask library,or during a scan. In general, movement of the object tables MT, WT willbe realized with the aid of a long-stroke module (coarse positioning)and a short-stroke module (fine positioning), which are not explicitlydepicted in FIG. 9. However, in the case of a wafer stepper (as opposedto a step-and-scan tool) the mask table MT may just be connected to ashort stroke actuator, or may be fixed.

The depicted tool can be used in two different modes:

-   -   In step mode, the mask table MT is kept essentially stationary,        and an entire mask image is projected in one go (i.e., a single        “flash”) onto a target portion C. The substrate table WT is then        shifted in the x and/or y directions so that a different target        portion C can be irradiated by the beam B;    -   In scan mode, essentially the same scenario applies, except that        a given target portion C is not exposed in a single “flash”.        Instead, the mask table MT is movable in a given direction (the        so-called “scan direction”, e.g., the y direction) with a speed        v, so that the projection beam B is caused to scan over a mask        image; concurrently, the substrate table WT is simultaneously        moved in the same or opposite direction at a speed V=Mv, in        which M is the magnification of the lens PL (typically, M=¼ or        ⅕). In this manner, a relatively large target portion C can be        exposed, without having to compromise on resolution.

The concepts disclosed herein may simulate or mathematically model anygeneric imaging system for imaging sub wavelength features, and may beespecially useful with emerging imaging technologies capable ofproducing wavelengths of an increasingly smaller size. Emergingtechnologies already in use include EUV (extreme ultra violet)lithography that is capable of producing a 193 nm wavelength with theuse of an ArF laser, and even a 157 nm wavelength with the use of aFluorine laser. Moreover, EUV lithography is capable of producingwavelengths within a range of 20-5 nm by using a synchrotron or byhitting a material (either solid or a plasma) with high energy electronsin order to produce photons within this range.

While the concepts disclosed herein may be used for imaging on asubstrate such as a silicon wafer, it shall be understood that thedisclosed concepts may be used with any type of lithographic imagingsystems, e.g., those used for imaging on substrates other than siliconwafers.

The descriptions above are intended to be illustrative, not limiting.Thus, it will be apparent to one skilled in the art that modificationsmay be made to the embodiments as described without departing from thescope of the claims set out below.

What is claimed is:
 1. A computer-implemented method for tuning alithographic process to a reference lithographic process, thelithographic process being configured for imaging a portion of a designlayout onto a substrate using a lithographic projection apparatuscomprising an illumination source and projection optics, the methodcomprising: defining a multi-variable cost function of a plurality ofdesign variables that represent characteristics of the lithographicprocess, wherein the cost function represents a difference inlithographic response between the lithographic process and the referencelithographic process and wherein at least some of the design variablescomprise characteristics of the projection optics; and reconfiguring,using a computer, the characteristics of the lithographic process byadjusting the design variables until a predefined termination conditionis satisfied.
 2. The method of claim 1, wherein the referencelithographic process represents one of the following: a lithographicresponse of a reference lithographic projection apparatus; a desiredlithographic response of a virtual reference lithographic projectionapparatus; a lithographic response as measured from the portion of thedesign layout imaged on a reference substrate; and a lithographicresponse from a lithographic projection apparatus that is physicallyand/or characteristically different from the lithographic projectionapparatus being used to tune the lithographic process.
 3. The method ofclaim 1, wherein the portion of the design layout comprises one or moreof the following: an entire design layout, a clip, a section of a designlayout that is known to have one or more critical features, a section ofthe design layout where a hot spot or a warm spot has been identifiedfrom a full-chip simulation, and a section of the design layout whereone or more critical features have been identified by a patternselection method.
 4. The method of claim 1, wherein the predefinedtermination condition includes one or more of: minimization of the costfunction; maximization of the cost function; reaching a preset number ofiterations; reaching a value of the cost function equal to or beyond apreset threshold value; reaching a predefined computation time; and,reaching a value of the cost function within an acceptable error limit.5. The method of claim 1, wherein the method further comprises: usingvalues of the design variables to update the lithographic process whenthe predetermined termination condition is satisfied; comparing theupdated lithographic process with the reference lithographic process;and repeating the updating step and the comparing step until anadditional termination condition is satisfied.
 6. The method of claim 5,wherein the additional termination condition indicates an acceptablematching between the characteristics of the lithographic process and thereference lithographic process.
 7. The method of claim 1, wherein one ormore of the design variables are characteristics of the illuminationsource.
 8. The method of claim 1, wherein the reconfiguration step isperformed without constraints or with constraints dictating a range ofat least some of the design variables.
 9. The method of claim 8, whereinat least some of the design variables are under constraints representingphysical restrictions in a hardware implementation of the lithographicprojection apparatus.
 10. The method of claim 9, wherein the constraintsinclude one or more of: tuning ranges, rules governing maskmanufacturability, and interdependence between the design variables. 11.The method of claim 1, wherein the cost function is a function of adifference of one or more of the following lithographic metrics: edgeplacement error, critical dimension, resist contour distance, worstdefect size, and best focus shift.
 12. The method of claim 1, whereinthe method comprises, prior to performing the steps of the optimizationprocess, selecting a subset of target patterns that characteristicallyrepresents features of the portion of the design layout.
 13. The methodof claim 12, wherein identified hot spots or warm spots are convertedinto test patterns and are included in the subset of test patterns thatare used for a current optimization process.
 14. The method of claim 1,wherein optimization of various design variables are performedsimultaneously until the predefined termination condition is satisfied.15. The method of claim 1, wherein optimization of various designvariables are performed alternatively, keeping at least some of thedesign variables fixed while the other design variables are optimized,and repeating the alternative optimization process until the predefinedtermination condition is satisfied.
 16. The method of claim 1, whereinthe optimization process includes iteratively minimizing the costfunction by calculating linear fitting coefficients within predefinedrelatively small neighborhoods around a starting point in eachiteration.
 17. The method of claim 1, wherein the cost function isminimized by solving polynomials, including higher-order polynomials ofthe design variables.
 18. The method of claim 17, wherein the costfunction is expanded in terms of fitting constant coefficients.
 19. Themethod of claim 18, wherein the fitting constant coefficients arecomputed from coefficients from polynomial expansion of transmissioncross coefficients (TCCs).
 20. A computer program product comprising anon-transitory computer readable medium having instructions recordedthereon, the instructions when executed by a computer implementing themethod of claim 1.